Chiller assembly

ABSTRACT

A chiller assembly includes an enclosure having a separator panel provided therein that divides the enclosure into first and second compartments. The separator panel is mounted at an angle relative to the horizontal. A condenser is provided with the first compartment. A heat exchanger is provided with the second compartment. The heat exchanger and the condenser utilize refrigerant flowing therebetween to remove heat from a supply of fluid flowing through the heat exchanger. The enclosure includes a debris opening to provide access to debris collected on the separator panel when one of air and fluid is directed through the condenser in a direction towards the separator panel during a cleaning operation of the condenser.

BACKGROUND OF THE INVENTION

This invention relates in general to industrial or medical coolantchiller assemblies. Chiller assemblies are used in conjunction withprocesses or applications as heat exchangers for removing heat fromfluids. Chilled fluid is delivered by the chiller assembly to theprocess. The process increases the temperature of the fluid. The fluidis then returned to the chiller assembly, where the fluid is cooled andthen again delivered to the process. Thus, the fluid is cycled betweenthe chiller assembly and the process. Various examples of processes orapplications that utilize chilled fluids include machine tool equipment,lasers, water jet cutting tools, medical equipment, food systems,chemical systems, heat treatment equipment, filtration systems,semi-conductor systems, welding processes, vapor degreasing systems,power generation, and dry cleaning equipment. Common fluids that areused include water, water/glycol, coolant fluids, lubricants, oils,acids, EDM (electrical discharge machining) fluids, and gasoline.

Chiller assemblies are generally designed to deliver the fluid to theprocess or application at a desired temperature. Typical chillerassemblies include a closed loop heat exchange system using arefrigerant to remove heat from the fluid. The heat exchange systemsgenerally include a condenser, a heat exchanger and/or evaporator, and amotor driven compressor. These components are housed in an enclosure,which typically includes a top mounted exhaust fan. The condenserincludes conduits such as coils, a plurality of tubes, or a series ofplates through which the refrigerant flows through. The conduits aremechanically connected to a plurality of metal fins such that theconduits are cooled by air forced over the fins and conduits by theexhaust fan. The cooling of the conduits generally causes therefrigerant flowing inside the conduits to condense from a warmergaseous state to a cooler liquid state. The cooled liquid refrigerantthen is directed to the evaporator or heat exchanger, where the cooledliquid refrigerant is used to lower the temperature of the fluid. Afterthe heat exchange within the evaporator or heat exchanger, thenow-heated refrigerant is directed back to the condenser, while thecooled process fluid is directed back to the process. Thus, the heatfrom the fluid is removed by the air which is forced over the fins andconduits by the exhaust fan. Typically, the condenser is a mounted in aside opening formed in the enclosure of the coolant chiller assembly.The exhaust fan may be mounted in an upper opening formed in a top roofpanel of the enclosure. The exhaust fan pulls air through the sideopening and through the condenser, then exhausts the heated air throughthe upper opening.

After a period of use, the conduits and fins of the condenser mayaccumulate dust, dirt, and foreign matter which unfortunately act as aninsulative coating, thereby reducing the efficiency of the condenser.This dust, dirt, and foreign matter also may restrict the air flowthough the condenser. The reduced efficiency may be even worse forcondensers which are made from aluminum compared to ones made fromcopper due to their generally smaller, thinner, and more compact design.In the past, the condensers were cleaned by directing, air, water, orother fluid at the condenser to release the dust, dirt, and foreignmatter. However, the newly released dust, dirt, and foreign matter canform debris which may inadvertently be directed at the evaporator,compressor, motors, and other components within the coolant chillerenclosure. To avoid contaminating the components, the condenser may beremoved and then cleaned. However, this is also undesirable due to thetime involved, and it further prevents the coolant chiller from beingused during cleaning.

SUMMARY OF THE INVENTION

This invention relates to chiller assemblies and, in particular, to achiller assembly that includes an enclosure having a separator panelprovided therein that divides the enclosure into first and secondcompartments. The separator panel is mounted at an angle relative to thehorizontal. A condenser is provided within the first compartment. A heatexchanger is provided within the second compartment. The heat exchangerand the condenser utilize refrigerant flowing therebetween to removeheat from a supply of fluid flowing through the heat exchanger. Theenclosure includes a debris opening to provide access to debriscollected on the separator panel when one of air and fluid is directedthrough the condenser in a direction towards the separator panel duringa cleaning operation of the condenser.

Various aspects of this invention will become apparent to those skilledin the art from the following detailed description of the preferredembodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a first embodiment of a chillerassembly.

FIG. 2 is a rear perspective view of the enclosure of the chillerassembly of FIG. 1.

FIG. 3 is a front elevational view of the enclosure of FIG. 2.

FIG. 4 is a side view of the enclosure of FIG. 2.

FIG. 5 is an enlarged partial cross-sectional view taken along lines 5-5of FIG. 3 illustrating a hinged debris door mounted on the enclosure.

FIG. 6 is schematic a side elevational view of a second embodiment of anenclosure.

FIG. 7 is a schematic side elevational of a third embodiment of anenclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, there is illustrated in FIG. 1 a firstembodiment of a chiller assembly, which is indicated generally at 10.The assembly 10 may be used to cool any type of fluid for use in aprocess or machine. The fluid enters the assembly 10 at an inlet conduit12 and exits the assembly 10 at an outlet conduit 14. The assemblyremoves heat from the fluid entering the inlet conduit 12 and dischargesthe fluid at the outlet conduit 14 at a desired temperature or at adesired temperature differential. Hoses or conduits (not shown) can beconnected to the inlet and outlet conduits 12 and 14 and connected tothe various machines and processes. It should be understood that theassembly 10 can be used with any application, machine, or process whichutilizes fluids. Examples of processes or applications that may be usedwith the assembly 10 include machine tool equipment, lasers, water jetcutting tools, medical equipment, food systems, chemical systems, heattreatment equipment, filtration systems, semi-conductor systems, weldingprocesses, vapor degreasing systems, power generation, and dry cleaningequipment. It should also be understood that any fluid may be usedbetween the assembly 10 and the process. Examples of such fluids includewater, water/glycol, coolant fluids, lubricants, oils, acids, EDM(electrical discharge machining) fluids, gasoline, and other fuels. Injust one possible example, the inlet and outlet conduits 12 and 14 ofthe assembly 10 may be connected with a machine tool (not shown) whichsprays the fluid directed at a workpiece and a cutting tool. The fluidprovides lubrication, removes metal chips, and cools the cutting tooland workpiece during a cutting or machining operation. The fluid issprayed onto the cutting tool and workpiece and collected afterwards.The collected fluid is then sent to the assembly 10, where the fluid iscooled and then delivered back to the machine tool.

The assembly 10 includes an enclosure 20 which houses various componentsof the assembly 10. As shown in FIGS. 1 through 4, the enclosure 20 canhave a generally rectangular box-like shape. Of course, the enclosure 20can have any suitable shape for housing the components. The enclosure 20can be formed from any material, such as generally flat metal sheetingwhich may be riveted, welded, glued or otherwise connected together. Theillustrated enclosure 20 includes a front wall 22, a rear wall 24, leftand right sides 26 and 28, a top panel 30, and a lower panel 32. Theenclosure 20 may also include feet 33 to slightly raise the lower panel32 from the floor which the assembly 10 is resting on. The enclosure 20also includes a separator panel 34 mounted within the interior of theenclosure 20. The separator panel 34 may be generally mounted on anangle relative to the horizontal, the reason for which will be explainedbelow. The separator panel 34 separates the interior of the enclosure 20into two compartments: a condenser compartment 36 and a componentcompartment 38. More details of the enclosure 20 will be explainedbelow.

The assembly 10 also includes a condenser 40, an exhaust fan 42, and acontrol panel 44, as shown in FIG. 1. As schematically shown in FIG. 4,the assembly 10 also generally includes a heat exchanger assembly 46, acompressor 48, and a motor 50 for driving the compressor 48. Theassembly 10 may also include a pump 51. The control panel 44 may beconnected to a power source (not shown) and can include controls andgauges for controlling the various components of the assembly 10. Thecondenser 40 and the exhaust fan 42 are generally mounted within thecondenser compartment 36. Alternatively, the condenser 40 and theexhaust fan 42 may be partially located within the condenser compartment36 or mounted on the exterior of the enclosure 20. The heat exchangerassembly 46, the compressor 48, and the motor 50 are generally locatedwithin the component compartment 38. The pump 51 cycles the fluidthrough the inlet and outlet conduits 12 and 14, thereby delivering thefluid between the desired application or process and the chillerassembly 10. The pump 51 may be provided as part of the assembly 10 oralternatively may be provided with the process and, thus, not housedwithin the enclosure 20.

In the embodiment shown in FIGS. 1 through 5, the condenser 40 has arelatively flat planar shape and is housed adjacent an opening 60 formedin the front wall 22 of the enclosure 20. The opening 60 communicateswith the condenser compartment 36. The condenser 40 may be formed as aconventional condenser unit including a plurality of relatively narrowconduits, through which refrigerant flows through. The conduits may beformed as small passageways formed in structures with a relatively largecollective outer surface. Examples of suitable conduits are coils, aplurality of tubes, or series of plates. The conduits may be arranged ina coil-like pattern such that the refrigerant flows through a singlepath. Alternatively, the conduits can be arranged such that there aremultiple flow paths. The condenser 40 may also be configured such that aplurality of generally thin fins is connected to the conduits. The finsfunction as heat sinks and help provide heat transfer when air flowspast the heat fins and conduits. The condenser 40 may be supportedwithin the enclosure 20 by supports 62 attached to the inside face ofthe front wall 22. In the illustrated embodiment, there is provided apair of supports 62 formed from bent and shaped sheet metal. Thesupports 62 are attached to a lower portion 66 of the separator panel20, as best shown in FIG. 5.

The top panel 30 includes an opening 68 formed therein. The opening 68communicates with the condenser compartment 36. The exhaust fan 42 maybe mounted on the enclosure 20 adjacent the opening 68. The exhaust fan42 may be mounted above the top panel 30, as shown in FIG. 1, below thetop panel 30, or within the opening 68. It should be understood that theopening 68 and exhaust fan 42 may be located on any exterior panel orwall of the enclosure 20.

During operation of the coolant chiller assembly 10, the exhaust fan 42provides air flow into the enclosure 20 through the opening 60, throughthe condenser 40, and out of the enclosure 20 through the opening 68.Thus, air is directed over the conduits and fins of the condenser 40.The flow of air over the conduits and fins provides for heat transferbetween the fluid within the conduits and the ambient air. Thecompressor 48 is operated to pump refrigerant through the conduits ofthe condenser 40. Cooling of the conduits causes the refrigerant thereinto cool and to condense from a warmer gaseous sate to a cooler liquidstate. The cooled liquid refrigerant then is directed to an evaporatorof the heat exchanger assembly 46 where the cooled liquid refrigerant isused to lower the temperature of the fluid. The heat exchanger assembly46 includes separate conduits containing the refrigerant and the fluidwhich are positioned adjacent one another for heat exchange purposes.The fluid and the refrigerant are generally not commingled. After theheat exchange, the now-heated refrigerant is directed back to thecondenser 40, while the cooled fluid is directed back to the process ormachine.

It is sometimes desirable to clean the condenser 40 after a period oftime to remove dust, dirt, and foreign matter which may accumulate onthe conduits and fins thereof. The condenser 40 can be cleaned bydirecting, air, water, or other fluid in a direction at a front face 70of the condenser 40 to release the dust, dirt, and foreign matter on theconduits and fins of the condenser 40. The air, water, or other fluidmay be directed by an applicator 72 as shown schematically in FIG. 1.The applicator 72 can be a spray gun or hose which forces air, water orother fluid at a relatively high velocity at the condenser 40. Theapplicator 72 is simply manually moved to direct the spray across theface 70 of the condenser 40 to dislodge the dust, dirt, and foreignmatter from the surfaces of the conduits and fins of the condenser 40.The dislodged dust, dirt, and foreign matter, as well as the water orfluid if so used, form debris which is dispersed within the interior ofthe condenser compartment 36. The separator panel 34 provides a barrierbetween the dispersed debris and the various components housed withinthe component compartment 38 of the assembly 10. The separator panel 34is preferably mounted at a non-zero degree angle relative to thehorizontal such that gravity will collect the debris on the separatorpanel 34. The shape and/or angled mounting of the separator panel 34 mayalso assist in moving the debris downwardly to a collection region 76,as best shown in FIG. 5. The collection region 76 may simply be adjacentthe lower portion 66 of the separator panel 34. The collection region 76may be below a lower edge 41 of the condenser 40 such that debrisremoved from the lower portion of the condenser 40 will collect on theseparator panel 34 and be moved to the collection region 76. To easilyremove the debris from the collection region 76, the enclosure 20 mayhave a debris opening 80 formed therein. In the illustrated enclosure20, the debris opening 80 is a slot located under the lower edge of thecondenser 40 and generally extends to the sides of the enclosure 20. Thedebris opening 80 may have the same general width as the width of thefront face 70 of the condenser 40. The enclosure 20 may also include adoor 84 movably mounted on the enclosure 20 for selectively covering andexposing the debris opening 80. The door 84 may be mounted by a hinge 86connected to an upper portion of the door 84. The door 84 may be simplylifted upwardly to a position (indicated by 84′) to remove the debrisfrom the collection region 76. Since the debris opening 80 is incommunication with the condenser compartment 36, the door 84 ispreferably in its closed position during operation of the assembly 10 tohelp prevent air flow through the debris opening 80. Thus, the door 84provides for an easy manner for removing the debris during a cleanoutoperation, while maintaining air flow efficiency during operation of theassembly 10.

In the embodiment of the enclosure 20 illustrated in FIGS. 1 through 5,the separator panel 34 extends across the entire width of the enclosure20 and is attached to the side panels 26 and 28 of the enclosure 20.Side edges 88 of the separator panel 34 may be attached to the sidepanels 26 and 28 by riveting mounting flanges 90 formed along the sideedges 88 of the separator panel 34 to the side panels 26 and 28 of theenclosure 20. The mounting flanges 90 may be simply an edge portion ofthe side edges 88 which are bent at a ninety degree angle. Also, anupper edge 92 of the separator panel 34 may extend all the way to therear wall 24 and/or the top panel 30 of the enclosure 20. A lower edge94 of the separator panel 34 may also extend all the way to the frontwall 22 of the enclosure 20. In this configuration, the separator panel34 substantially seals the condenser compartment 36 from the componentcompartment 38. This may be advantageous in that the sealedconfiguration prevents debris from entering the component compartment 38during a cleaning operation and also provides for an efficient air flowpath though the condenser 40 when the exhaust fan 42 moves air from theopening 60 out through the upper opening 68. However, it should beunderstood that the separator panel 34 may be sized and configured suchthat none, one, or more than one of the side edges 88, the upper edge92, or the lower edge 94 does not attach directly to one of the outerwalls of the enclosure 20, thereby leaving a gap and, therefore, notsealing the compartments 36 and 38 from one another. This may beadvantageous if some air flow is desired through the componentcompartment 38 for cooling off the components therein. Thus, while theseparator panel 34 separates and defines the condenser compartment 36and the component compartment within the interior of the enclosure 20,the two compartments 36 and 38 need not be fully sealed from oneanother, although they may be if so desired. Also, the enclosure 20 mayfurther include other compartments therein which are separated from thecondenser compartment 36 or the component compartment 38 from otherpanels (not shown). The enclosure 20 may also include vent openings,such as openings 97 formed through the rear wall 24, to provideventilation of the component compartment 38.

The separator panel 34 may be formed by a single part, such as a singlesheet as shown in the illustrated embodiment in FIGS. 1 through 5, ormay be formed from a plurality of parts connected together orindividually connected to various structures of the enclosure 20. Asshown in FIG. 5, the lower portion 66 of the separator panel 34 may beslightly angled from the main portion of the separator panel 34 at abend 98 to accommodate the mounting of the separator panel 34 to thesupports 62 and the walls of the enclosure 20.

The separator panel 34 may be made of any suitable material, such assheet metal. However, it should be understood that any material, such asplastic, may be used instead. The separator panel 34 may also include acoating or outer layer to reduce the adhesion of debris thereto so thatthe debris is more likely to slide downwardly into the collection region76.

In the embodiment of the enclosure 20 illustrated in FIGS. 1 through 5,the separator panel 34 has generally flat planar shape. It should beunderstood that the separator panel 34 may have any suitable shape whichpreferably functions to separate the enclosure 20 into the condensercompartment 36 and the component compartment 38 while also directing anydebris to the collection region 76. If the separator panel 34 is angledrelative to the horizontal, gravity may assist in capturing and thensliding any debris downwardly along an upper surface 35.

The separator panel 34 may have a curved or sloped shape either in theside direction or front-to-rear direction. For example, there isschematically illustrated in FIG. 6 an alternate embodiment of a chillerassembly 100 having an enclosure 101 including a differently shapedseparator panel 102. In the embodiment illustrated in FIG. 6, theseparator panel 102 has a curved or sloped shape. The separator panel102 is shaped to permit gravity to direct any debris collected thereondownwardly. Debris is directed to a collection region 104 under thelower edge 106 of the condenser 108.

Another difference of the enclosure 101 compared to the enclosure 20 isthat instead of a hinged door 84, the enclosure 101 includes a movablymounted collection tray 110. The tray 110 may be slidably mounted alonga track 112 or may be movably mounted by any other suitable mountingarrangement. The illustrated embodiment of the tray 110 includes a frontwall 114 which selectively covers a debris opening 116. The tray 110 canbe moved to a position indicated by 110′ or can be completely removed todump the debris after a cleanout operation. The tray 110 can have anysuitable shape. For example, the tray 110 may be in the form of a drawerhaving a bottom panel and one or more vertical side walls. The tray 110may also be a flat plate. The tray 110 may also include a funnel shapedportion (not shown) which collects debris in a localized area. A conduitor hose may be connected to the funnel portion for directing the debristo a desired holding area or drainage area. The tray 110 may also be anysize for collecting and removing debris. For example, the tray 110 maybe located under a lower portion 113 of the separator panel 102 andsized to fit in the collection region 104. Alternatively, the tray 110may extend in a longer direction towards the rear of the enclosure 100.In an alternative embodiment not shown, the tray and separator panel maybe combined as a unit such that a portion or the entire separator panelmay be removed from the enclosure to easily dispose of the debris.

The separator panel 102 divides the interior of the enclosure 101 into acondenser compartment 120 and a component compartment 122. It is notedthat the lower portion 113 of the separator panel 102 does not extendall the way to a front wall 124 of the enclosure 101. Thus, theseparator panel 102 does not completely seal the condenser compartment120 from the component compartment 122. However, this configurationstill permits airflow, as represented by arrow 126, through thecondenser 108 by an exhaust fan (not shown) in a similar manner asdescribed above with respect to the assembly 10.

The enclosure 101 may also be configured such that the tray 110 isremoved from a side wall, rear wall, or top panel of the enclosure 101instead of the front wall 124. For example, the enclosure 101 could beconfigured with a side opening formed in the side wall of the enclosure101 instead of the opening 116 in the front wall 124.

There is illustrated in FIG. 7 another embodiment of a coolant chillerassembly 130 having an enclosure 132 and a pair of condensers 134.During operation of the assembly 130, air flow, as represented by arrows133, flows through the condenser 108 by an exhaust fan (not shown) in asimilar manner as described above with respect to the assembly 10. Theenclosure 132 further includes a separator panel 136 having an invertedV-shape such that there are two collection regions 139. The separatorpanel 136 defines a pair of downwardly sloping portions 137. Thecollection regions 139 are located adjacent respective debris openings140 having hinged doors 142 functioning in a similar manner as theenclosure 20 described above.

The principle and mode of operation of this invention have beenexplained and illustrated in its preferred embodiments. However, it mustbe understood that this invention may be practiced otherwise than asspecifically explained and illustrated without departing from its spiritor scope.

1. A chiller assembly comprising: an enclosure having a separator panelprovided therein that divides said enclosure into first and secondcompartments and that is mounted at an angle relative to the horizontal,a condenser provided within said first compartment; and a heat exchangerprovided within said second compartment, wherein said heat exchanger andsaid condenser utilize refrigerant flowing therebetween to remove heatfrom a supply of fluid flowing through said heat exchanger; wherein saidenclosure includes a debris opening to provide access to debriscollected from said separator panel.
 2. The assembly of claim 1, whereinthe debris opening is located below said condenser and adjacent a lowerportion of said separator panel for collecting debris when one of airand fluid is directed through said condenser in a direction towards saidseparator panel during a cleaning operation of said condenser.
 3. Theassembly of claim 1, wherein the enclosure includes a removable debristray located adjacent said debris opening.
 4. The assembly of claim 1,wherein said enclosure includes a door movably mounted on said enclosurefor selectively covering and exposing said debris opening.
 5. Theassembly of claim 1, wherein said enclosure includes a verticallyoriented front panel, said front panel having said debris opening and anopening receiving said condenser formed therein.
 6. The assembly ofclaim 1, wherein said separator panel has a flat planar shape.
 7. Theassembly of claim 1, wherein said separator panel has a curved shape. 8.The assembly of claim 1, wherein said separator panel is formed from asingle panel.
 9. The assembly of claim 1, wherein said separator panelseals said first compartment from said second compartment such that thedebris will not be introduced into said second compartment during thecleaning operation.
 10. The assembly of claim 1, wherein said condenseris vertically mounted in said first opening.
 11. The assembly of claim 1further including an exhaust fan mounted in a second opening of saidenclosure, wherein said second opening communicates with said firstcompartment.
 12. A chiller assembly comprising: an enclosure having aseparator panel provided therein that divides said enclosure into firstand second compartments and that is mounted at an angle relative to thehorizontal, said separator panel sealing said first compartment fromsaid second compartment; a condenser provided within said firstcompartment; an exhaust fan mounted in a second opening of saidenclosure, wherein said second opening communicates with said firstcompartment; a heat exchanger provided within said second compartment,wherein said heat exchanger and said condenser utilize refrigerantflowing therebetween to remove heat from a supply of fluid flowingthrough said heat exchanger; wherein said enclosure includes a debrisopening located below said first opening to provide access to debriscollected on said separator panel when one of air and fluid is directedthrough said condenser in a direction towards said separator panelduring a cleaning operation of said condenser, and wherein saidenclosure includes a door movably mounted on said enclosure forselectively covering and exposing said debris opening.
 13. A chillerassembly comprising: an enclosure defining an interior; a separatorpanel disposed within the interior of the enclosure and dividing theinterior of the enclosure into first and second compartments, theseparator panel being oriented at an angle relative to the horizontal; aremovable debris tray provided within said first compartment; acondenser provided within the first compartment; and a heat exchangerprovided within the second compartment and in fluid communication withthe condenser, the condenser and the heat exchanger adapted to lower thetemperature of a fluid passing through the heat exchanger.
 14. Theassembly of claim 13, wherein said debris tray is located adjacent abottom portion of said separator panel for collecting debris when one ofair and fluid is directed through said condenser in a direction towardssaid separator panel during a cleaning operation of said condenser.